Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/50—Polyethers having heteroatoms other than oxygen
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4804—Two or more polyethers of different physical or chemical nature
  • C08G18/482—Mixtures of polyethers containing at least one polyether containing nitrogen
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/08—Processes
  • C08G18/16—Catalysts
  • C08G18/18—Catalysts containing secondary or tertiary amines or salts thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/42—Polycondensates having carboxylic or carbonic ester groups in the main chain
  • C08G18/46—Polycondensates having carboxylic or carbonic ester groups in the main chain having heteroatoms other than oxygen
  • C08G18/4615—Polycondensates having carboxylic or carbonic ester groups in the main chain having heteroatoms other than oxygen containing nitrogen
  • C08G18/4623—Polycondensates having carboxylic or carbonic ester groups in the main chain having heteroatoms other than oxygen containing nitrogen containing primary or secondary terminal aminogroups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/50—Polyethers having heteroatoms other than oxygen
  • C08G18/5021—Polyethers having heteroatoms other than oxygen having nitrogen
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/50—Polyethers having heteroatoms other than oxygen
  • C08G18/5021—Polyethers having heteroatoms other than oxygen having nitrogen
  • C08G18/5069—Polyethers having heteroatoms other than oxygen having nitrogen prepared from polyepoxy compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
  • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
  • C08J9/125—Water, e.g. hydrated salts
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/22—After-treatment of expandable particles; Forming foamed products
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/16—Nitrogen-containing compounds
  • C08K5/17—Amines; Quaternary ammonium compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0008—Foam properties flexible
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0041—Foam properties having specified density
  • C08G2110/005—< 50kg/m3
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0083—Foam properties prepared using water as the sole blowing agent

Definitions

• the present invention pertains to the use of acid blocked, amine-based, autocatalytic polyols, and to the use of these autocatalytic polyols in the production of polyurethane foams.
• Polyether polyols based on the polymerization of alkylene oxides, and/or polyester polyols, are the major components of a polyurethane system together with isocyanates.
• Polyols can also be filled polyols, such as SAN (Styrene/Acrylonitrile) , PIPA (polyisocyanate polyaddition) or PHD (polyurea) polyols, as described in "Polyurethane Handbook", by G. Oertel, Hanser publisher.
• These systems generally contain additional components such as blowing agents, cross-linkers, chain extenders, surfactants, cell regulators, stabilizers, antioxidants, flame retardant additives, eventually fillers, and typically catalysts such as tertiary amines and/or organometallic salts.
• Organometallic catalysts can raise environmental issues due to leaching upon aging of the polyurethane products . Others, such as tin salts, are often detrimental to polyurethane aging.
• Tertiary amine catalysts generally have a strong odor and many are highly volatile due to their low molecular weight.
• the release of the tertiary amine during foam processing may present safety and toxicity concerns and the release of residual amine during customer handling is undesirable.
• the release of tertiary amine catalysts vapor in polyurethane products are also reported to be detrimental to vinyl film and polycarbonate sheets exposed thereto.
• the tertiary amine catalysts present in polyurethane foams have been linked to the staining of the vinyl film and degradation of polycarbonate sheets.
• the PVC staining and polycarbonate decomposition problems are especially prevalent in environments where elevated temperatures exist for prolonged periods of time.
• Various solutions are proposed to reduce the emission of the volatile catalyst.
• amine catalysts which contain a hydrogen isocyanate reactive group, i.e. a hydroxyl or a primary and/or a secondary amine.
• a hydrogen isocyanate reactive group i.e. a hydroxyl or a primary and/or a secondary amine.
• Such compounds are, for instance, disclosed in EP Publications 677,540; 747,407 and EP 1,109,847; and in U.S. Patents 3,448,065; 4,122,038; 4,368,278 and 4,510,269.
• a reported advantage of this catalyst composition is that these amines are incorporated into the polyurethane product.
• reactive catalysts have to be used at high levels in the polyurethane formulation to compensate for their lack of mobility during the foaming reactions and since most of them are monofunctional they act as chain stoppers.
• these reactive amine catalysts have a detrimental effect on the polymer build up and affect polyurethane product physical characteristics, especially foam aging.
• Acid blocked amine catalysts are also used to produce polyurethane foams, as described for example in U.S. Patents 4,366,084; 5,179,131; 4,232,152 and EP 1 457 507.
• Amines blocked with specific hydrocarboxylic acids are disclosed in US 5,489,618. Advantages reported with such catalysts disclosed in the ⁇ 131, ⁇ 618 and EP Publication are more open foams, reduced amine emissions and improved foam tear characteristics. However, there is no mention of foam aging improvements.
• Unbalanced reactivity translates in flexible foams with reduced hardness, or load-bearing, and worse aging properties compared to foams made with fugitive catalysts, such as triethylenediamine and bis-dimethylamionoethyl-ether.
• An example of unbalanced reactivity profile is for instance reported in "Polyurethane Chemistry and Technology", by J.H. Saunders and K.C. Frisch, John Wiley publisher, part 1, page 334, which states that "factors favoring bad ( high compression) set ...include: large excess of water in foam formulation, high amine catalyst concentration, very active catalyst for the NC0/H20 reaction.”
• VOC volatile organic compounds
• the use of such polyols allows the production of polyurethane products in the absence or reduction of conventional amine based and/or organometallic catalysts. With the elimination or reduction of conventional amine and organometallic catalysts, the disadvantages associated with such catalysts can be avoided.
• the present invention is a process for the production of a polyurethane foam by reaction of a mixture of
• a polyol composition comprising (bl) from 0 to 99 percent by weight of a polyol compound having a functionality of 2 to 8 and a hydroxyl number of from 15 to 300 mg KOH/gram and
• (b2) from 1 to 100 by weight of at least one polyol compound having a functionality of 2 to 8, a hydroxyl number of from 15 to 300 mg KOH/gram and containing at least one tertiary amine group providing autocatalytic function, wherein a portion of the tertiary amine is acid neutralized and the weight percent of polyol is based on the total amount of polyol composition (b) ; (c) in the presence of water as a blowing agent; and (d) optionally additives or auxiliary agents known per se for the production of polyurethane foams, including catalysts .
• the invention is the production of a polyurethane foam as above where polyol (bl) comprises 75 percent or greater by weight of total polyol (bl) and (b2) and polyol (b2) has a hydroxyl number of 20 to 800.
• the invention is a polyol composition
• a polyol composition comprising from 0 to 99 percent by weight of a polyol compound having a functionality of 2 to 8 and a hydroxyl number of from 15 to 300 mg KOH/gram and from 1 to 100 by weight of at least one polyol compound having a functionality of 2 to 8, a hydroxyl number of from 15 to 800, generally from 15 to 300 mg KOH/gram containing at least one tertiary amine group providing autocatalytic function and an acid capable of neutralizing/blocking the tertiary amine group.
• the present invention is a process whereby polyol (b2) is a combination of two autocatalytic polyols, one with blowing characteristics (promotes the reaction of water with a polyisocyanate) , and the other with gelling characteristics (promotes the reaction of polyol with an isocyanate) .
• the present invention is a process whereby there is no other catalyst besides an acid blocked, amine based, autocatalytic polyols (b2) or a combination of such polyols .
• the present invention is a process whereby autocatalytic polyol (b2) is an alkylene oxide adduct of an initiator bearing N-methyl and/or N,N-dimethyl amino groups, or is capped with N-methyl and/or N,N-dimethyl or a pyrrolidine group or an imidazole.
• the present invention is a process whereby polyol (b2) is a blend of amine initiated and amine capped polyols.
• the acid used to partially block the amine moiety of autocatalytic polyol (b2) is a carboxylic acid.
• the acid used to partially block the amine moiety of autocatalytic polyol (b2) is a carboxylic acid containing at least one hydroxyl moiety.
• polyol (bl) is also an amine based, autocatalytic polyol, but without acid neutralization.
• autocatalytic polyol (b2) is partially acid neutralized and is blended with an amine catalyst which is not acid neutralized.
• the present invention is a process whereby the blowing agent (c) is only water.
• the present invention is a process whereby the polyurethane foam is a flexible foam.
• the present invention is a process whereby the polyurethane foam is molded. In another embodiment the present invention is a process whereby the polyurethane foam density is less than 70 kg/m3.
• the present invention is a process whereby the polyurethane molded parts are demolded in less than 8 minutes. In another embodiment the present invention is a process whereby the polyurethane foam is used to produce multihardness foams, i.e, parts with different hardnesses.
• the present invention is a process whereby the polyurethane foam is used to produce automotive seats and padding.
• the present invention is a process as disclosed above wherein the polyisocyanate (a) contains at least one polyisocyanate that is a reaction product of an excess of polyisocyanate with an amine based, autocatalytic polyol.
• the present invention is a process as disclosed above where the polyol (b) contains a polyol-terminated prepolymer obtained by the reaction of an excess of polyol with a polyisocyanate wherein the polyol is defined by (b2) .
• the invention further provides for polyurethane foams produced by any of the above processes.
• a polyol formulation and the use of the formulation for producing polyurethane products is provided, whereby the polyurethane products can be produced with a reduced level of volatile tertiary amine catalysts.
• the reduction of volatile compounds reduces or eliminates issues associated with emission of such compounds.
• the use of such a polyol formulation also provides a polyurethane catalyst system which gives good foam processing, i.e. a minimal level of scrap, while the physical characteristics of the foam made therefrom, such as foam load- bearing, tear strength, tensile strength and elongation, as well as foam aging, are not adversely affected and may even be improved by the reduction/elimination of conventional or reactive amine and/or organometallic catalysts.
• polyols are those materials having at least one group containing an active hydrogen atom capable of undergoing reaction with an isocyanate.
• Preferred among such compounds are materials having at least two hydroxyls, primary or secondary, or at least two amines, primary or secondary, carboxylic acid, or thiol groups per molecule.
• Compounds having at least two hydroxyl groups or at least two amine groups per molecule are especially preferred due to their desirable reactivity with polyisocyanates.
• Suitable polyols (b) that can be used to produce polyurethane foams of the present invention are well known in the art and include those described herein and any other commercially available polyol and/or SAN, PIPA or PHD copolymer polyols. Such polyols are described in "Polyurethane Handbook", by G. Oertel, Hanser publishers. Mixtures of one or more polyols and/or one or more copolymer polyols may also be used to produce polyurethane products according to the present invention.
• polyols include polyether polyols, polyester polyols, polyhydroxy-terminated acetal resins, hydroxyl-terminated amines and polyamines. Examples of these and other suitable isocyanate-reactive materials are described more fully in U.S. Patent 4,394,491.
• Alternative polyols that may be used include polyalkylene carbonate-based polyols and polyphosphate-based polyols.
• Catalysis for this polymerization can be either anionic or cationic, with catalysts such as KOH, CsOH, boron trifluoride, or a double cyanide complex (DMC) catalyst such as zinc hexacyanocobaltate, or quaternary phosphazenium compounds.
• catalysts such as KOH, CsOH, boron trifluoride, or a double cyanide complex (DMC) catalyst such as zinc hexacyanocobaltate, or quaternary phosphazenium compounds.
• DMC double cyanide complex
• these are eliminated from the polyol at the end of production by a proper finishing step, such as coalescence, magnesium silicate (magsil) separation, ion exchange or less preferably by acid neutralization.
• the polyols or blends thereof employed depend upon the end use of the polyurethane foam to be produced.
• the hydroxyl number and molecular weight of the polyol or polyols employed can vary accordingly over a wide range. In general, the hydroxyl number of the polyols employed for use in producing a flexible or visco-elastic foam may range from 15 to 300.
• the polyol is preferably a polyether polyol and/or a polyester polyol.
• the polyol generally has an average functionality- ranging from 2 to 5, preferably 2 to 4, and an average hydroxyl number ranging from 15 to 300 mg KOH/g, preferably from 20 to 200, and more preferably from 20 to 70mg KOH/g.
• the specific foam application will likewise influence the choice of base polyol.
• the hydroxyl number of the base polyol may be on the order of 20 to 60 with ethylene oxide (EO) capping, and for slabstock foams the hydroxyl number may be on the order of 25 to 75 and is either mixed feed EO/PO (propylene oxide) or is only slightly capped with EO or is 100 percent PO based.
• EO ethylene oxide
• polyols having a functionality as for flexible foam can be used, however; the polyol or polyol blend will preferably contain polyols having a hydroxyl number from 150 to 300 mg KOH/g.
• the polyol or polyol blend will preferably contain polyols having a hydroxyl number from 150 to 300 mg KOH/g.
• a trifunctional polyol with a hydroxyl number of 30 to 80.
• the initiators for the production of polyols (bl) generally have 2 to 8 functional groups that will react with the alkylene oxide.
• Suitable initiator molecules are water, organic dicarboxylic acids, such as succinic acid, adipic acid, phthalic acid and terephthalic acid and polyhydric, in particular dihydric to octahydric alcohols or dialkylene glycols, for example ethanediol, 1,2- and 1, 3-propanediol, diethylene glycol, dipropylene glycol, 1, 4-butanediol, 1,6- hexanediol, glycerol, trimethylolpropane, pentaerythritol, sorbitol and sucrose or blends thereof.
• organic dicarboxylic acids such as succinic acid, adipic acid, phthalic acid and terephthalic acid
• polyhydric in particular dihydric to octahydric alcohols or dialkylene glycols, for example ethanediol, 1,2- and 1, 3-propanediol, diethylene glycol,
• Initiators of polyol (bl) can also be of the same type as for polyol (b2), i.e. linear and cyclic amine compounds containing a tertiary amine such as ethanoldiamine, triethanoldiamine, isomers of toluene diamine, isomers of diaminodiphenylmethane, ethylenediamine, N- methyl-l,2-ethanediamine, N-Methyl-1,3-propanediamine, N,N- dimethyl-1, 3-diaminopropane, N,N-dimethylethanolamine, 3,3'- diamino-N-methyldipropylamine, N.N-dimethyl-1, 4-diaminobutane, N,N-dimethyl-l, 3-diaminopropane, N,N- dimethyldipropylenetriamine, aminopropyl-imidazole, N- aminoethylpiperazine, N- (amin
• the acid blocked, amine based, autocatalytic polyol (b2) is generally a liquid at room temperature and is preferably substantially free of any alkali metals used in production of the polyol, such as potassium, sodium or cesium.
• the polyol accelerates preferably the addition reaction of organic polyisocyanates with polyhydroxyl or polyamino compounds, but may also be active on the reaction between the isocyanate and water.
• the combination of autocatalytic polyols (b2) will be used in the present invention together with conventional polyols (bl) , including copolymer polyols of the SAN, PHD or PIPA type.
• the properties of the autocatalytic polyols can vary widely as described above for polyol (bl) in terms of number average molecular weight, hydroxyl number, functionality, etc.
• polyol (b2) is the predominant polyol used in a formulation
• the hydroxyl number, functionality etc. will generally be as described above for the particular desired foam characteristics.
• the hydroxyl number, functionality etc. can deviate substantially from the normal values used in a particular application.
• less than the predominant polyol component means less than 25 percent, generally less than 15, preferably less than 10 and in some applications less than 5 percent by weight of the total polyol component.
• the level of (b2) polyol when producing a slabstock foam the level of (b2) polyol can be less than 5 percent by weight of the total polyol.
• the hydroxyl number of the polyol i.e., number average molecular weight
• the catalytic activity of the polyol increases. This increase in catalytic activity is generally believed to be due to an increase in the concentration of tertiary amines per polyol on a weight bases and increased basicity.
• Autocatalytic polyols (b2) are based on a tertiary amine, such as those made from an amine initiator.
• the initiator contains at least one N-alkyl amino group, where the alkyl group contains from 1 to 6 carbon atoms and preferably from 1 to 3 carbon atoms, and in one preferred embodiment, the alkyl group is methyl. In another preferred embodiment, the initiator contains at least one N,N-dialkyl amino group where the alkyl is as previously described.
• amines can also be capped with a tertiary amine, following, for instance the process described in WO 03/55930.
• the amine can also be incorporated in the PO/EO chain of the polyol or be part of a polymer as described in WO 2004/060956.
• Amine based polyol (b2) with autocatalytic characteristics can be also those containing a tertiary nitrogen in the chain, by using for instance an alkyl-aziridine as co-monomer with PO and EO, or (b2) can be polyols capped with a tertiary amine, by using for example a N,N-dialkyl-glycidylamine as taught in US 3,428,708.
• amine based, autocatalytic polyols are those containing at least one imine linkage and at least one tertiary amine group, for instance such as those made by reaction of an epoxy resin having an EEW (epoxy equivalent weight) of at least 150, with the phenol group of salicyladehyde, and subsequent reaction of the aldehyde moiety with a tertiary amine bearing a primary amine group, such as, for instance, N- (aminoalkyl) - pyrrolidine, or 3-dimethylamino-l-propylamine or 1(3- aminopropyl) -imidazole. Processes for the production of such polyols is described in WO2005/063840.
• Examples of commercially available amine initiators for producing the polyols of (b2) include triethylenetetramine, ethylenediamine, N-methyl-1,2-ethanediamine, N-methyl-1,3- propanediamine, N,N-dimethyl-l,3-diaminopropane, N,N-dimethyl- 1,4-diaminobutane, N,N-dimethyldipropylenetriamine, N,N- dimethyl-tris (hydroxymethyl) aminomethane can be made by methylation of tris-amino, or tris (hydroxymethyl)aminomethane; an aminoalcohol commercially available from ANGUS Chemical, diamino or dihydroxy derivatives of piperazine such as N-bis(2- amino-isobutyl) - piperazine, 3, 3' -diamino-N-methyldipropylamine; 2,2' -diamino-N-methyldiethylamine; 2,3-diamin
• Acid blocking agents are preferably combined with a diluent, or a solvent when they are solid, such as glycols or water, and the acid is slowly added to the polyol under stirring while exotherm is controlled via proper cooling of the reactor.
• the acids used to neutralize the autocatalytic polyol (b2) can be organic acids, such as carboxylic acids or amino-acids or saturated or unsaturated fatty acids, or non-organic acids, such as sulfuric or phosphoric acids, or blends thereof.
• these acids are carboxylic, such as formic or acetic acids, and more preferably they contain a hydroxyl functionality, as described in US patent 5,489,618, the disclosure of which is incorporated herein by reference.
• the carboxylic or hydroxyl carboxylic compounds generally have from 1 to 20 carbon atoms and preferably from 1 to 10 carbon atoms and may be linear or branched or may be cyclic when the compound contains 4 or more carbon atoms. It is also contemplated that the compounds can contain more than one ' carboxyl group or hydroxyl groups for the hydroxyl carboxylic acid compounds.
• Other preferred acids are carboxylic acids containing halofunctionality or aryloxy substituted carboxylic acids, as described in EP 1,018,525 and EP 1,018,526 respectively, or they can be acid grafted polyethers, such as those described in US 4,701,474.
• the molar ratio between the acids and the amines present in polyols (b2) is less than 0.8, which means that no more than 80 % of the amines are neutralized.
• the total tertiary amines present in the polyurethane formulation is preferably less than 0.8, which means than not more than 80 % of the total tertiary amines present is neutralized. More preferably these amines are neutralized at less than 50 %, i.e. only 50 % or less of the tertiary nitrogens present in the foam formulation are acid blocked. Even more preferably, the acid or acids neutralize less than 30 % of the total amines.
• At least 0.1 percent, preferably at least 0.5 percent and more preferably at least 1 percent of the total amines are acid blocked or acid neutralized.
• the acid used to block the autocatalytic polyol (b2) will eventually neutralize some of the polyol (bl), when it also contains nitrogen moieties, and any other amine, once the components for producing a foam, such as polyols, water, any catalyst, surfactant, crosslinker, etc. are blended.
• the acid may also react with metal salts or other amines present in the formulation.
• amine based catalyst such as triethylenediamine, dimethylethanolamine, etc, or metal salts catalysts, such as stannous octoate, or amine based crosslinkers, such a.s diethanolamine.
• the weight ratio of acid blocked, amine based, autocatalytic polyol (b2) to polyol (bl) will vary depending upon the reaction profile required by the specific application. Usually polyol (b2) will be used at levels up to 100 parts, but preferably at a level below 80 parts, and more preferably at a level below 50 parts. Polyol (bl) is preferably present at a level of at least 0.5 percent, more preferably 1.0 percent or greater by weight of the total polyol (b) .
• the combination acid blocked autocatalytic polyol (b2) and polyol (bl) is added in an amount so that the curing time is equivalent where the reaction mix contains at least 10 percent by weight less conventional catalyst.
• the combination of (bl) and (b2) is added to give a reaction mixture containing 20 percent less catalyst than the base level. More preferably the addition of (bl) and (b2) will reduce the amount of catalyst required by 30 percent over the base level.
• the most preferred level of (bl) and (b2) addition is where the need for conventional, fugitive or reactive tertiary amine catalysts or organometallic salt is eliminated.
• Combination of two or more acid blocked, amine based, autocatalytic polyols (b2) can also be used with satisfactory results in a single polyurethane formulation when one wants for instance to adjust blowing and gelling reactions modifying for instance the amine structures of the autocatalytic polyol (b2) with different tertiary amines, functionalities, equivalent weights, etc, and their respective amounts in the formulations.
• Combination of different acids to neutralize autocatalytic polyol (b2) can also be contemplated for the same reason, i.e. adjustment of reaction profile and eventually of delayed action.
• Polyols pre-reacted with polyisocyanates and polyol (b2) with no free isocyanate functions can also be used in the polyurethane formulation.
• Isocyanate prepolymers based on polyol (b2) can be prepared with standard equipment, using conventional methods, such a heating the polyol (b2) in a reactor and adding slowly the isocyanate under stirring and then adding eventually a second polyol, or by prereacting a first polyol with a diisocyanate and then adding polyol (b2) .
• the isocyanates which may be used with the autocatalytic polymers of the present invention include aliphatic, cycloaliphatic, arylaliphatic and aromatic isocyanates.
• Aromatic isocyanates, especially aromatic polyisocyanates are preferred.
• suitable aromatic isocyanates include the 4,4'-, 2,4' and 2,2 '-isomers of diphenylmethane diisocyante (MDI) , blends thereof and polymeric and monomeric MDI blends toluene-2,4- and 2, 6-diisocyanates (TDI), m- and p- phenylenediisocyanate, chlorophenylene-2, 4-diisocyanate, diphenylene-4, 4 '-diisocyanate, 4,4'-diisocyanate-3, 3 ' - dimehtyldiphenyl, 3-methyldiphenyl-methane-4,4'-diisocyanate and diphenyletherdiisocyanate and 2, 4, 6-triisocyanatotoluene and 2,4,4'-triisocyanatodiphenylether.
• MDI diphenylmethane diisocyante
• TDI polymeric and monomeric MDI blend
• isocyanates may be used, such as the commercially available mixtures of 2,4- and 2,6-isomers of toluene diisocyantes .
• a crude polyisocyanate may also be used in the practice of this invention, such as crude toluene diisocyanate obtained by the phosgenation of a mixture of toluene diamine or the crude diphenylmethane diisocyanate obtained by the phosgenation of crude methylene diphenylamine.
• TDI/MDI blends may also be used.
• MDI or TDI based prepolymers can also be used, made either with polyol (bl) , polyol (b2) or any other polyol as described heretofore.
• Isocyanate-terminated prepolymers are prepared by reacting an excess of polyisocyanate with polyols, including aminated polyols or imines/enamines thereof, or polyamines.
• polyols including aminated polyols or imines/enamines thereof, or polyamines.
• aliphatic polyisocyanates include ethylene diisocyanate, 1, 6-hexamethylene diisocyanate, isophorone diisocyanate, cyclohexane 1, 4-diisocyanate, 4,4'- dicyclohexylmethane diisocyanate, saturated analogues of the above mentioned aromatic isocyanates and mixtures thereof.
• the preferred polyisocyantes for the production of rigid or semi-rigid foams are polymethylene polyphenylene isocyanates, the 2,2', 2,4' and 4,4' isomers of diphenylmethylene diisocyanate and mixtures thereof.
• the preferred polyisocyanates are the toluene- 2,4- and 2, 6-diisocyanates or MDI or combinations of TDI/MDI or prepolymers made therefrom.
• Isocyanate tipped prepolymer based on polyol (b2) can also be used in the polyurethane formulation.
• a blowing agent is generally required.
• water is preferred as the blowing agent.
• the amount of water is preferably in the range of from 0.5 to 10 parts by weight, more preferably from 2 to 7 parts by weight based on 100 parts by weight of the polyol.
• other blowing agents can be liquid or gaseous carbon dioxide, methylene chloride, acetone, pentane, isopentane, cyclopentane, methylal or dimethoxymethane, dimethylcarbonate.
• Use of artificially reduced, or increased, atmospheric pressure, such as disclosed in US 5,194,453, or frothing, can also be contemplated with the present invention.
• polyurethane polymers In addition to the foregoing critical components, it is often desirable to employ certain other ingredients in preparing polyurethane polymers.
• additional ingredients are surfactants, preservatives, flame retardants, colorants, antioxidants, reinforcing agents, stabilizers and fillers, recycled polyurethane powder.
• Reduced amounts of conventional, fugitive catalysts can also be used with this invention, such as triethylenediamine, bis-dimethylaminoethyl-ether, and stannous octoate.
• Low VOC catalysts based on reactive amines, such as, for instance, dimethylethanolamine, or tin ricinoleate, such as Kosmos EF, sold by Godschmidt AG, division of Degussa, can also be combined with acid neutralized, autocatylic, amine-based polyols of the present invention.
• a surfactant advantageously comprise a liquid or solid organosilicone surfactant.
• surfactants include polyethylene glycol ethers of long-chain alcohols, tertiary amine or alkanolamine salts of long-chain alkyl acid sulfate esters, alkyl sulfonic esters and alkyl arylsulfonic acids. Such surfactants are employed in amounts sufficient to stabilize the foaming reaction mixture against collapse and the formation of large, uneven cells. Typically, 0.2 to 3 parts of the surfactant per 100 parts by weight total polyol (b) are sufficient for this purpose .
• a crosslinking agent or a chain extender may be added, if necessary.
• the crosslinking agent or the chain extender includes low-molecular weight polyhydric alcohols such as ethylene glycol, diethylene glycol, 1, 4-butanediol, and glycerin; low-molecular weight amine polyol such as diethanolamine and triethanolamine; polyamines such as ethylene diamine, xlylenediamine, and methylene-bis (o-chloroaniline) .
• crosslinking agents or chain extenders are known in the art as disclosed in U.S. Patents 4,863,979, 4,883,825 and 4,963,399 and EP 549,120.
• a flame retardant is sometimes included as an additive.
• Any known liquid or solid flame retardant can be used with the autocatalytic polyols of the present invention.
• flame retardant agents are halogen-substituted phosphates and inorganic flame proofing agents.
• Common halogen-substituted phosphates are tricresyl phosphate, tris (1, 3-dichloropropyl phosphate, tris (2,3-dibromopropyl) phosphate and tetrakis (2- chloroethyl) ethylene diphosphate.
• Inorganic flame retardants include red phosphorous, aluminum oxide hydrate, antimony trioxide, ammonium sulfate, expandable graphite, urea or melamine cyanurate or mixtures of at least two flame retardants.
• flame retardants are added at a level of from 5 to 50 parts by weight, preferable from 5 to 25 parts by weight of the flame retardant per 100 parts per weight of the total polyol present.
• the applications for foams produced by the present invention are those known in the industry. Flexible, semi- flexible foams and find use in applications such as bedding, furniture, automobile seats, sun visors, armrests, door panels, noise and heat insulation parts.
• the polyurethane products are either produced continuously or discontinuously, by injection, pouring, spraying, casting, calendering, etc; these are made under free rise or molded conditions, with or without release agents, in-mold coating, or any inserts or skin put in the mold.
• release agents in-mold coating, or any inserts or skin put in the mold.
• those can be mono- or dual-hardness.
• DEOA is 85 % diethanolamine in water.
• DMAPA 3- (N, N-dimethylamino) propylamine.
• Niax Y-10184 is a silicone based surfactant
• Dabco DC 5169 is a silicone-based surfactant available from Air Products and
• Dabco 33 LV is a tertiary amine catalyst available from Air Products and Chemicals Inc.
• Niax A-I is a tertiary amine catalyst
• Niax A-300 is an acid-blocked amine catalyst
• glycolic Acid is a 70 % solution in water of hydroxyl-carboxylic acid available from Aldrich.
• Gluconic acid is a 50 % solution in water available from Aldrich.
• Formic acid is 96 percent purity, carboxylic acid available from Aldrich.
• D.E.R. 732 is an aliphatic epoxy resin with an
• Polyol A i s the reaction product of D . E . R .
• Polyol B is a 1 , 700 equivalent weight propoxylated tetrol initiated with
• Specflex NC-630 is a 1 , 700 EW polyoxypropylene polyoxyethylene polyol initiated with a blend of glycerol and sucrose available from The Dow Chemical
• Polyol C is a polyol similar to Specflex NC
• Specflex NC 632 is a high functionality polyol similar to Specflex NC 630 available from The Dow Chemical Company
• Voranol 4053 is a high EO containing hexol, used as a cell opener available from The
• Voranol 4701 is a glycerol initiated polyol available from The Dow Chemical
• SPECFLEX NC-700 is a 40 percent SAN based copolymer polyol with an average hydroxyl number of 20 available from The Dow Chemical Company.
• Copolymer polyol D is a 43 percent SAN based copolymer polyol similar to Specflex NC-700 with a 20 percent EO carrier polyol.
• VORANATE T-80 is TDI 80/20 isocyanate available from The Dow Chemical Company.
• Foams made in the laboratory on the bench are produced by preblending polyols, surfactants, crosslinkers, catalysts and water, conditioned at 25°C. Isocyanate also conditioned at 25°C is added under stirring at 3,000 RPM for 5 seconds. At the end of mixing the reactants are poured in a 30x30x10 cm aluminum mold heated at 60 0 C which is subsequently closed. Prior to use, the mold is sprayed with a release agent. Foam curing at 6 minutes is assessed by manually demolding the part, looking for internal and external defects. If none, the part is rated as OK. Free-rise foams are produced by pouring the reactants in a 5 gallon bucket.
• Machine made foams are prepared using a Cannon high pressure machine. Mold size is 40x40x10 cm and demolding time is 6 minutes 30 seconds. All foams are tested according to ASTM D-3574-83 test methods.
• Example 3C is a comparative example
• HACS Humid Aged Compression Set.
• the foam is aged at 100 % Relative humidity and 125°C for 5 hours, before running the normal dry compression set.
• the positive effect of the addition of glycolic acid in example 4 of this invention is quite clear. It is also important to note that only a very small amount of conventional amine catalyst (Niax A-I) is used.
• polyol B To 100 grams of polyol B is added 0.35 grams of glycolic acid. This partial salt of amine based polyol is only slightly hazy. The partial salt is stored for two weeks at room temperature and is found to be stable. A blend of this acid- blocked polyol and other polyols and additives, as described in example 9 hereafter, is also tested for eventual metal corrosion. No corrosion is found after aging of this polyol blend in presence of a carbon steel sample for three weeks at 80 0 C.
• VHS Very Slightly Hazy
• SH Slightly Hazy
• C Clear
• H Hazy
• WP White Precipitate
• examples 6 and 7 confirms that a salt is formed between polyol B, an amine initiated polyol, and the acid. This is confirmed by NMR tests carried out on a JEOL 400 MHz spectrometer at a Carbon-13 frequency of 100.5 MHz on similar polyol + acid solutions . Comparative example 7Cl shows that that Niax A-300, a commercially available amine salt catalyst, is not readily compatible with polyol B.
• *8C is a comparative example.
• polyol B an autocatalytic, amine initiated, polyol is partially neutralized with glycolic acid and then a conventional amine catalyst, Dabco 33 LV, is added. After thorough mixing a stable, hazy solution/dispersion is obtained. NMR spectra confirm that all of these components are present as partial salts in the blend.
• an amine catalyst salt between Dabco 33 LV and glycolic acid is produced according to the teaching of US 5,489,618. This amine salt is then added to polyol B. However, the salt is found to be incompatible and stays in a separate phase as confirmed by NMR data showing neither TEDA (the amine of Dabco 33 LV or triethylenediamine) or glycolic acid peaks.
• Foams are prepared without an amine co-catalyst on a bench scale according to the formulations of Table 5.
• *9C is a comparative example.
• Examples 10, 11 and 12 Good molded foams were produced on the bench with the formulations given in Table 6. These formulations are based on various amounts of Specflex NC 700 copolymer polyol to give different foam hardnesses for use in seat cushions, backrest or bolsters. No amine catalysts are needed as the combination of autocatalytic polyols A and B partially neutralized with glycolic acid give the appropriate reactivity profile to these formulations. No amine odors are noticed at demold.
• Molded parts are produced with a Krauss-Maffei KM-40 machine, using the formulations in Table 7.
• the formulations give foams having good 75 % compression set properties. Demolding time is 6 and 5 minutes respectively for examples 13 and 14 (mold volume about 20 liters) . TABLE 7

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• 2005
  • 2005-11-14 WO PCT/US2005/040798 patent/WO2006055396A1/en active Application Filing
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